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Am I correct in thinking that bees hived on foundation always chew away the foundation at the bottom bar leaving a gap? Or is it only some bees sometimes? I try to draw most of my brood chambers as honey supers which avoids this problem, but always isn't possible such as with my 11 1/4" deep frames. They did a fair job on some 4.9 in the honey super.

Not always, but I see it often. Sometimes they chew it part way up one side too. I have heard speculation, that seemed reasonable, that perhaps it makes a better "dance ground" since the bees have to go by vibration, since it's dark in the hive.